U.S. patent application number 10/577248 was filed with the patent office on 2007-09-20 for lining support plate and associated production method.
Invention is credited to Cristobal Montero Bautista, Armin Eckert, Carsten Heider.
Application Number | 20070215305 10/577248 |
Document ID | / |
Family ID | 34529930 |
Filed Date | 2007-09-20 |
United States Patent
Application |
20070215305 |
Kind Code |
A1 |
Heider; Carsten ; et
al. |
September 20, 2007 |
Lining Support Plate and Associated Production Method
Abstract
The invention relates to a lining support plate and to an
associated production method. According to the inventive method, a
support plate pattern (1) comprising several cavities (4) in a
lateral face is provided. Pins (6a-6d) are inserted into the
cavities in such a way that the pins (6a-6d) partially protrude
from the support plate pattern (1). The support plate pattern (1)
and the sections of the pins (6a-6d) that protrude from the pattern
are subsequently surrounded by a moulding compound and the latter
is compressed and/or cured. After the compression and/or curing
process, the support plate pattern (1) is removed from the moulding
compound in such a way that the pins (6a-6d) are left behind in the
latter and a support plate casting cavity is formed. A melt is
poured into the cavity, surrounding the sections of the pins
(6a-6d) that protrude into the support plate casting cavity. Once
the melt has solidified, the lining support plate can be removed
from the mould. Preferably the melt forms a cast iron containing
vermicular graphite during the solidification process.
Inventors: |
Heider; Carsten; (Burscheid,
DE) ; Bautista; Cristobal Montero; (Essen, DE)
; Eckert; Armin; (Waltrop, DE) |
Correspondence
Address: |
Charles P Boukus Jr
2001 Jefferson Davis Highway
Suite 202
Arlington
VA
22202
US
|
Family ID: |
34529930 |
Appl. No.: |
10/577248 |
Filed: |
October 21, 2004 |
PCT Filed: |
October 21, 2004 |
PCT NO: |
PCT/EP04/11915 |
371 Date: |
January 24, 2007 |
Current U.S.
Class: |
164/75 ;
164/141 |
Current CPC
Class: |
F16D 2069/0433 20130101;
F16D 69/04 20130101; F16D 2069/0441 20130101 |
Class at
Publication: |
164/075 ;
164/141 |
International
Class: |
B22D 19/00 20060101
B22D019/00 |
Foreign Application Data
Date |
Code |
Application Number |
Oct 30, 2003 |
DE |
103 50 725.6 |
Claims
1. A method of producing a lining support plate in which: a) a
support plate pattern is prepared, whereby the support plate
pattern has on one lateral face which corresponds to the face of
the support plate facing a friction lining a plurality of recesses
into each of which a pin is introduced in such a way that the pin
partially projects out of the support plate pattern; b) the support
plate pattern and the portions of the pins projecting out of the
support plate pattern are surrounded by a moulding compound, the
moulding compound is compressed and/or cured, the support plate
pattern is removed from the cured and/or compressed moulding
compound in such a way that the pins with the portions projecting
out of the support plate pattern remain in the moulding compound
and a support plate casting is formed into which the pins protrude;
c) a melt is poured into the support plate casting cavity, whereby
the portions of the pins protruding into the support plate casting
cavity are surrounded by the melt; d) the melt is left to solidify
in such a way that a cast iron lining support plate is formed; and
e) the lining support plate is removed from the mould.
2. A method as claimed in claim 1, wherein the pins introduced into
the support plate pattern are constructed in such a way that the
portions of the pins projecting out of the pattern have
undercuts.
3. A method as claimed in claim 1, wherein the portions of pins
introduced into the recesses in the support plate are
contoured.
4. A method as claimed in claim 1, characterised in that when the
melt solidifies it forms a cast iron with vermicular graphite.
5. A lining support plate with a cast metal base plate with a
support surface to receive a friction lining material, wherein the
retaining elements project out of the support surface,
characterised in that the base plate is made from cast iron, and
that the retaining elements are pins which are cast into the base
plate during the production thereof in such a way that in each case
a portion of the pins projects out of the support surface of the
base plate.
6. A lining support plate as claimed in claim 5, characterised in
that the base plate is produced from cast iron with vermicular
graphite.
7. A lining support plate as claimed in claim 5, characterised in
that the pins are constructed in such a way that the portions of
the pins projecting out of the base plate have undercuts.
8. A lining support plate as claimed in claim 5, characterised in
that a portion of the pins cast into the base plate during
production thereof is contoured.
9. A method of producing a friction lining, in which a lining
support plate is produced according to a method as claimed in claim
1, and a friction lining material with an organic binder is pressed
onto the lateral surface of the lining support plate having the
pins.
10. A friction lining with a lining support plate as claimed in
claim 5 and a friction lining material, wherein a friction lining
with an organic binder is pressed onto the support surface.
Description
[0001] The invention relates to a method of producing a lining
support plate. The invention further relates to a lining support
plate with a cast metal base plate with a support surface to
receive a friction lining material, wherein retaining elements
project out of the support surface.
[0002] Brake and clutch linings usually comprise a support plate
with a friction lining material pressed onto it. In order to
improve the adhesion between the support plate and the friction
lining material an adhesive is frequently applied to the support
plate before the friction lining material is pressed on. This
adhesive is generally an adhesive based on a phenolic resin. If
need be an underlayer material can be disposed between the adhesive
and the friction lining material to damp vibrations occurring
during the braking operation. In such brake and clutch linings the
support plate is made from steel. A disadvantage of the usual
construction of a brake or clutch lining is, on the one hand, that
the adhesive often does not withstand the high temperatures and
shear forces which occur in the friction lining during braking. In
some circumstances this leads to a detachment of the friction
lining material from the support plate and thus to destruction of
the brake or clutch lining. On the other hand, because of the steel
used in the production of the support plate the weight of such an
arrangement is very high.
[0003] In order to solve the problem of the adhesive which does not
withstand the high temperatures and shear forces, friction linings
have been developed in which the connection between the support
plate and the friction lining material has been improved. Thus for
example holes can be introduced into the support plate. These can
be filled with friction lining material during compression. Thus a
connection between the friction lining material and the support
plate is produced which withstands the shear forces better. It is
known for example for a plurality of depressions to be introduced
by laser beams into the surface of the support plate facing the
friction lining, whereby some of the material removed from the
depressions is thrown up on the edge thereof.
[0004] Furthermore, it is known to produce retaining elements on
the side of the support plate facing the friction lining material.
This can be done in such a way that either the retaining elements
are worked out of the support plate material, for example in the
form of an indentation and/or machining, or the retaining elements
are applied to the support plate, for example in the form of
lattices or pins which are welded or sintered on.
[0005] However, the methods referred to above for the improvement
of the connection between the support plate and the friction lining
material are not suitable for reducing the weight of a friction
lining, since all methods are based on a support plate made from
steel.
[0006] The object of the present invention is to provide friction
linings of reduced weight with an improved connection between a
friction lining material and a lining support plate.
[0007] This object is achieved according to the invention by a
method of producing a lining support plate with the features of
claim 1, or by a lining support plate with the features of claim 5
or by a method of producing a friction lining with the features of
claim 9 or by a friction lining with the features of claim 10.
[0008] According to the invention a lining support plate is
produced in which: [0009] a) a support plate pattern is prepared,
whereby the support plate pattern has on one lateral face which
corresponds to the face of the support plate facing a friction
lining a plurality of recesses into each of which a pin is
introduced in such a way that the pin partially projects out of the
support plate pattern; [0010] b) the support plate pattern and the
portions of the pins projecting out of the support plate pattern
are surrounded by a moulding compound, [0011] the moulding compound
is compressed and/or cured, [0012] the support plate pattern is
removed from the cured and/or compressed moulding compound in such
a way that the pins with the portions projecting out of the support
plate pattern remain in the moulding compound and a support plate
casting cavity is formed into which the pins protrude; [0013] c) a
melt is poured into the support plate casting cavity, whereby the
portions of the pins protruding into the support plate casting
cavity are surrounded by the melt; [0014] d) the melt is left to
solidify in such a way that a cast iron lining support plate is
formed; and [0015] e) the lining support plate is removed from the
mould.
[0016] A pin should be understood here to mean any body which
extends over a given length in such a way that over a part of this
length it can be introduced into a recess in the lining support
plate pattern, for example a body of any shape which is at least
partially cylindrical or conical.
[0017] By the use of a melt which solidifies to form a cast iron
support plate a reduction in weight of the lining support plate is
achieved. This is an increasingly important aspect of the
production of friction linings, since the automobile industry is
making efforts to reduce the overall weight of its motor vehicles
in order to lower their fuel consumption. Furthermore, the
reduction in the weight of the lining support plate leads to a
reduction in the transport costs.
[0018] By comparison with producing projecting retaining elements
from the cast material itself (for example through recesses in a
moulding compound on the basis of projections from a support plate
model), the introduction of pins during casting offers the
advantage that the pins cannot be sheared off and are anchored
better in the lining support plate.
[0019] The introduction of the pins by casting round also avoids
machining steps on the cooled cast lining support plate in order to
create retaining elements. These machining steps on the one hand
require additional processing time and costs and on the other hand
are more difficult to carry out with cast materials than with
steel.
[0020] In the method referred to above the recesses in the support
plate pattern can be provided with a plurality of different pins.
Thus it is possible for the type of pins which are introduced into
the support plate pattern to be varied within the surface of the
support plate patterns provided with the recesses in order to
control the type and/or the thickness of the anchoring in different
regions of the support plate. For example, in the regions of the
support plate which are subjected to particularly high shear forces
during braking pins which have particularly good anchoring
properties between support plate and friction lining material can
be used.
[0021] The pins introduced into the support plate pattern are
advantageously constructed in such a way that the portions of the
pins projecting out of the pattern have at least one portion which
tapers towards the lining support surface, i.e. at least one
undercut. When the lining support material is pressed together with
pins having the undercuts a positive-locking connection which is
particularly suitable for absorbing the shear forces occurring
during the braking operation is created between the friction lining
material and the pins of the support plate. In addition it is
possible for the number and the shape of the pins having the
undercuts to be adapted to the shear forces prevailing in different
regions of the support plate.
[0022] It is particularly advantageous if the portions of the pins
introduced into the recesses in the support plate pattern have a
contouring at least in part which is designed in such a way that
the pins can be introduced releasably into the support plate
pattern. The contouring should be understood here to mean any
surface configuration of the pin portions which deviates from a
smooth-walled cylindrical or conical pin shape. For example the
portions of the pins are provided with grooves or a thread. When
the melt is poured into the support plate casting cavity these
portions of the pins which protrude into the support plate casting
cavity are surrounded by the melt. In this way a particularly good
anchoring of the pins in the support plate is achieved.
[0023] In the method according to the invention it is advantageous
that when the melt solidifies it forms a cast iron with vermicular
graphite. The physical properties of cast iron with vermicular
graphite lie between those of a cast iron with spheroidal graphite
and those of a cast iron with flaked graphite. Advantageously on
the one hand the strength and impact resistance of the cast iron
with vermicular graphite is higher than in cast iron with flaked
graphite and on the other hand the vibration damping is better than
in cast iron with spheroidal graphite.
[0024] Furthermore, in order to achieve the object stated in the
introduction a lining support plate is proposed with a cast metal
base plate with a support surface to receive a friction lining
material, wherein retaining elements project out of the support
surface, characterised in that the base plate is made from cast
iron, and that the retaining elements are pins which are cast into
the base plate during production thereof in such a way that in each
case a portion of the pins projects out of the support surface of
the base plate.
[0025] Further advantageous and/or preferred variants of the
invention are characterised in the subordinate claims.
[0026] The invention is described in greater detail below with
reference to a preferred embodiment which is illustrated in the
drawings, in which:
[0027] FIG. 1 shows a schematic sectional view of a support plate
pattern inlaid into a case,
[0028] FIG. 2 shows a schematic sectional view of a support plate
pattern inlaid into a case with pins introduced into the support
plate pattern, and
[0029] FIG. 3 shows a schematic sectional view of a compressed
and/or cured moulding compound with pins disposed in it.
[0030] FIG. 1 shows a schematic sectional view of a support plate
pattern 1 inlaid into a case 2. The support plate pattern 1 and the
case 2 are disposed on a pattern plate 3. The support plate pattern
1 has a plurality of recesses 4 on the upwardly directed lateral
surface 5. The recesses 4 can be uniformly distributed over the
lateral surface 5, but they can also be disposed in variably dense
distribution in different part-regions, in which the density may be
a function of locally acting shear forces during braking. The
recesses 4 are preferably bores of identical diameter (simple
production). Alternatively the recesses 4 can have different
diameters in different regions of the lateral surface 5.
[0031] FIG. 2 shows a schematic sectional view of the support plate
pattern 1 inlaid into the case 2 with pins 6a to 6d introduced. As
is indicated schematically in FIG. 2, the portions of the pins 6a
to 6d projecting out of the support plate pattern 1 can be of
differing constructions. However, for reasons of simple production
the pins introduced into the recesses 4 are preferably of the same
shape and size. The pins can be constructed as circular cylinders
6a or as cylinders 6d which taper towards the end of the portion
projecting out of the support plate pattern 1. For improved
anchoring of the pins 6a to 6d in a friction lining material the
portions of the pins which project out of the support plate pattern
1 can have undercuts or can be of at least partially club-shaped
construction, as is indicated in the case of the pins 6c and 6d.
The portions of the pins 6a to 6d which protrude into the support
plate pattern 1 can be of cylindrical construction with smooth
walls. However, in order to produce a better anchoring in the
casting these portions preferably have a contouring, i.e. for
example peripheral grooves or a peripheral thread, as is indicated
in the case of the pin 6c.
[0032] After the support plate pattern 1 has been provided with a
plurality of pins 6a to 6d a moulding compound 7 is applied to the
support plate pattern 1. Then the applied moulding compound 7 is
compressed and/or cured. This can take place for example by the
application of pressure to the moulding compound. Furthermore, it
is possible to compress and/or to cure the moulding compound 7 by
vibration and/or heating.
[0033] After the compression and/or curing of the moulding compound
7 it is rotated by 180.degree. with the case 2 and the support
plate pattern 1 along the longitudinal axis of the pattern. Then
the support plate pattern 1 is removed from the moulding compound 7
in such a way that the portions of the pins 6a to 6d which project
out of the support plate pattern 1 in FIG. 2 remain in the moulding
compound. After the support plate pattern has been removed from the
moulding compound 7 it is covered with a second compressed and/or
cured moulding compound. The moulding compound 7 and the second
moulding compound for a support plate casting cavity 8. The second
moulding compound 7 has at least one riser and one sprue. In the
support plate casting cavity 8 formed by the moulding compound 7
and the second moulding compound a melt is poured in via the sprue,
whereby the portions of the pins 6a to 6d protruding into the
support plate cavity 8 are surrounded by the melt. Gases located n
the support plate cavity 8 and/or produced during the melting
operation can escape through the riser.
[0034] In the support plate casting cavity the melt is then left to
solidify in such a way that a cast iron support plate, preferably a
cast iron support plate with vermicular graphite, is formed. After
the solidification of the melt the cast iron support plate is
released from the casting mould. The riser and the sprue are
separated from the cast iron support plate and any moulding
compound still adhering is removed for example by sand blasting
apparatus.
[0035] Within the scope of the idea underlying the invention
numerous alternative embodiments are conceivable. For example,
covering of the moulding compound 7 by a second mould can be
omitted. The melt is then poured and metered into the moulding
compound 7. Shaping of the melt which is not delimited at the top
takes place by the force of gravity.
* * * * *